Torsion-resistant cable

Abstract

The utility model provides a torsion-resistant cable, which belongs to the technical field of cables and comprises a protection layer, a torsion-resistant layer and a torsion-resistant layer. The conductors are arranged in the protective layer, the number of the conductors is multiple groups, the multiple groups of conductors are annularly distributed, each group of conductors comprises a wrapping tape with the interior of a hollow structure, at least one circle of multiple strands which are annularly distributed is arranged in the wrapping tape, when the number of circles of the strands is multiple, the circle centers of the multiple circles of strands are located at the same point, and a cavity is reserved in the strand of the innermost circle; every two adjacent strands in each circle of strands are connected in an abutting mode. The plied yarn is made of a flexible material; the utility model has the advantages that: on one hand, the multi-group conductor annular distribution and single-group folded wire concentric circle nested structure is adopted, the torsion stress is uniformly dispersed along the circumferential direction, and the broken wire caused by local stress concentration is avoided; on the other hand, the hollow design of the wrapping tape and the folded wires and the cavity structure of the folded wire at the innermost ring are adopted; reversible deformation of the cable during torsion is allowed, and interlayer friction and metal fatigue are reduced.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, and in particular relates to a torsion-resistant cable. Background Technology

[0002] Cables used in wind power systems are critical components connecting wind turbines to the power grid, and their performance directly affects the stability and economy of the wind power system. Taking offshore wind power as an example, cables must meet the following extreme operating condition requirements:

[0003] Vertical suspension and frequent torsion: The cables inside the nacelle rotate automatically with the yaw system of the wind turbine, bearing long-term vertical suspension gravity (the self-weight of a single cable can reach several tons) and periodic torsional stress (the number of torsions per day can reach hundreds).

[0004] Corrosion from complex environments: Salt spray, oil, ultraviolet radiation, and seawater immersion cause cable sheath aging and conductor corrosion, especially for offshore wind power which needs to operate for more than 25 years in environments with salt spray concentrations exceeding 3%.

[0005] Accumulated mechanical fatigue: Due to insufficient elongation, aluminum conductors break due to stress concentration during repeated torsion, and the repair cost can be as high as 30% or more of the initial investment.

[0006] Given the aforementioned problems, existing torsion-resistant cables mostly employ a steel wire rope anti-torsion layer (such as an outer PTFE sheath + non-rotating steel wire rope). However, this type of structure is heavy and lacks flexibility, making it unsuitable for vertical suspended installation. Meanwhile, while shielding layer designs (such as composite braiding of poly(p-phenylene benzobisoxazole) fiber and copper wire) improve tensile strength, they do not solve the problem of stress concentration inside the conductor. Utility Model Content

[0007] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a torsion-resistant cable that allows for reversible deformation during torsion, thereby reducing interlayer friction and metal fatigue.

[0008] The objective of this utility model can be achieved through the following technical solution: a torsion-resistant cable, comprising:

[0009] The protective layer has an internally hollow structure;

[0010] A conductor is disposed within the protective layer. The conductor is in multiple groups, arranged in a ring. Each group of conductors includes a wrapping tape with a hollow internal structure. The wrapping tape contains at least one ring of multiple strands arranged in a ring. When there are multiple rings of strands, the centers of the multiple rings of strands are located at the same point, and the innermost ring of strands has a cavity. Adjacent strands in each ring are connected by contact. The strands are made of a flexible material.

[0011] In the aforementioned type of torsion-resistant cable, the conductor is formed by multiple strands twisted together in the same direction.

[0012] In the aforementioned torsion-resistant cable, the strands are formed by multiple conductor wires twisted together in the same direction, and the twisting direction of the strands is the same as the twisting direction of the conductor.

[0013] In the aforementioned type of torsion-resistant cable, the guide wire is made of aluminum.

[0014] In the aforementioned torsion-resistant cable, a tensile element is provided at the center of the protective layer, and the conductor is distributed around the tensile element and is in contact with the tensile element.

[0015] In the aforementioned type of torsion-resistant cable, the conductor is covered and wrapped with a rubber-coated cotton cloth tape to form a wrapping tape.

[0016] In the aforementioned torsion-resistant cable, an installation cavity is formed between two adjacent sets of conductors and the protective layer. An optical fiber sensor is installed in the installation cavity, and the optical fiber sensor is in contact with the corresponding conductor.

[0017] In the aforementioned torsion-resistant cable, the protective layer includes an insulating sleeve and a protective sleeve, with the insulating sleeve located inside the protective sleeve.

[0018] In the aforementioned torsion-resistant cable, the insulating sleeve is made of ethylene propylene rubber insulation, and the protective sleeve is made of chlorinated polyethylene.

[0019] In the aforementioned type of torsion-resistant cable, a non-woven fabric layer is also provided inside the insulating sleeve.

[0020] Compared with the prior art, the beneficial effects of this utility model are as follows: On the one hand, this utility model adopts a multi-group conductor ring distribution + single-group strand concentric circle nested structure to evenly distribute torsional stress along the circumference and avoid wire breakage caused by local stress concentration. On the other hand, this invention adopts a hollow design of wrapping tape and strands and a cavity structure of the innermost strand, which allows the cable to undergo reversible deformation when twisted, reducing interlayer friction and metal fatigue. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model.

[0022] In the diagram, 100 is the protective layer; 101 is the tensile element; 102 is the fiber optic sensor; 103 is the insulating sleeve; 104 is the protective sleeve; 105 is the non-woven fabric; 106 is the mounting cavity; 200 is the conductor; 201 is the wrapping tape; and 202 is the strand. Detailed Implementation

[0023] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0024] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0025] like Figure 1 As shown, a torsion-resistant cable includes:

[0026] Protective layer 100 has an internal hollow structure;

[0027] Conductors 200 are disposed within the protective layer 100. There are multiple groups of conductors 200 arranged in a ring. Each group of conductors 200 includes a wrapping tape 201 with a hollow internal structure. The wrapping tape 201 contains at least one ring of multiple strands 202 arranged in a ring. When there are multiple rings of strands 202, the centers of the multiple rings of strands 202 are located at the same point, and the innermost ring of strands 202 has a cavity. Adjacent strands 202 in each ring of strands 202 are connected by contact. The strands 202 are made of flexible material.

[0028] In this embodiment, through the ring distribution of multiple sets of conductors 200, the concentric nesting of single sets of conductor 200 strands 202, and the multi-level hollow structure design, combined with the strands 202 made of flexible material, a stress dispersion mechanism of "macroscopic circumferential stress balance and microscopic radial stress attenuation" is formed, effectively avoiding local stress concentration during torsion. The hollow structure of the protective layer 100, the wrapping tape 201, and the inner cavity provides space for elastic deformation. Combined with the rigid ring constraint of the strands 202 abutting connection, rigidity and flexibility are synergistic, improving fatigue resistance and structural stability, and ensuring conductivity reliability. Its ring abutting connection self-supporting characteristic can maintain the cross-sectional shape without additional filling material, reducing the skin effect. At the same time, the application of hollow structure and flexible aluminum strands 202 achieves lightweighting and low cost, making up for the performance shortcomings of aluminum conductors. Combined with moisture-proof and corrosion-resistant design, it meets the requirements for long-term stable operation in extreme environments. Through the deep synergy of geometric structure and material properties, the bottlenecks of traditional cables in terms of torsion resistance, reliability, and cost control are systematically broken through.

[0029] In the aforementioned type of torsion-resistant cable, the conductor 200 is formed by multiple strands 202 twisted together in the same direction.

[0030] In this embodiment, the conductor 200 is designed to be formed by multiple strands 202 twisted in the same direction. This twisting makes the strands 202 more regularly and orderly arranged, reducing friction and compression between them, and enhancing the overall flexibility of the conductor 200. This makes the cable more adaptable to deformation during torsion and less prone to damage. At the same time, this twisting method helps maintain the stability of the conductor 200 structure, preventing the strands 202 from loosening or shifting during frequent torsion, thus ensuring the stable conductivity of the conductor 200.

[0031] In the aforementioned type of torsion-resistant cable, the strand 202 is formed by multiple conductor wires twisted together in the same direction, and the twisting direction of the strand 202 is the same as the twisting direction of the conductor 200.

[0032] In this embodiment, the co-directional stranding method ensures that the guide wires are arranged closely and regularly within the strands 202 and within the conductor 200, enhancing the stability and compactness of the overall cable structure. This regular arrangement reduces friction between internal layers, allowing each layer to deform collaboratively during cable torsion, preventing structural damage and stress concentration caused by friction. Co-directional stranding also improves the cable's flexibility, enabling it to better adapt to frequent torsion conditions, reducing the risk of wire breakage and damage, ensuring stable and durable conductivity, and thus improving the cable's torsion resistance and service life.

[0033] In the aforementioned type of torsion-resistant cable, the conductor wire is made of aluminum.

[0034] In this embodiment, aluminum is used as the conductor material primarily because aluminum is lightweight, reducing the overall weight of the cable and making it easier to handle during installation and use, especially suitable for vertical laying scenarios, reducing the burden on the supporting structure. Simultaneously, aluminum's relatively low cost effectively controls cable production costs and enhances the product's market competitiveness. Furthermore, combined with the cable's inherent torsion-resistant structural design, it can compensate to some extent for aluminum's insufficient elongation, allowing the cable to possess good torsion resistance while leveraging the advantages of aluminum. This ensures stable operation of the cable under complex working conditions and achieves a balance between economic efficiency and performance.

[0035] In the aforementioned torsion-resistant cable, a tensile element 101 is provided at the center of the protective layer 100, and the conductor 200 is distributed around the tensile element 101 and is in contact with the tensile element 101.

[0036] In this embodiment, a tensile element 101 is provided at the center of the protective layer 100. This high-strength support frame, constructed at the core of the cable, effectively bears the longitudinal load of the cable under vertical laying or tensile conditions, preventing the conductor 200 from being damaged by excessive tensile force. The contact connection between the conductor 200 and the tensile element 101 forms a synergistic force-bearing structure. The rigid support of the tensile element 101 stabilizes the annular distribution of the conductor 200, reducing the disordered arrangement of the conductor 200 caused by tensile deformation. Simultaneously, it provides a torsional foundation for the entire cable, allowing torsional stress to be uniformly transmitted through the annular structure of the tensile element 101 and the conductor 200. This improves the cable's tensile performance while ensuring the stability of the torsional structure, making it suitable for harsh scenarios requiring simultaneous tensile and frequent torsion resistance.

[0037] In the aforementioned type of torsion-resistant cable, a rubber-coated cotton cloth tape is provided on the outside of the conductor 200 to cover and wrap it to form a wrapping tape 201.

[0038] In this embodiment, the conductor 200 is wrapped with a rubber-coated cotton tape to form a wrapping tape 201. The flexibility and insulation properties of the rubber-coated cotton tape effectively isolate the conductor 200 from the external environment, preventing moisture, oil, and other contaminants from corroding the conductor 200. It also provides buffer protection for the conductor 200, reducing frictional damage between the conductor 200 and other layers during torsion. This overlapping wrapping method creates a continuous and tight covering structure for the wrapping tape 201. This structure can adapt to the deformation during cable torsion, preventing the wrapping tape 201 from breaking or loosening. Furthermore, its elastic deformation helps to disperse stress, enhancing the structural stability of the conductor 200 assembly and ensuring that the wrapping tape 201 continues to provide insulation protection and mechanical support under long-term torsion and bending conditions.

[0039] In the aforementioned torsion-resistant cable, an installation cavity 106 is formed between two adjacent sets of conductors 200 and the protective layer 100. An optical fiber sensor 102 is installed in the installation cavity 106, and the optical fiber sensor 102 is in contact with the corresponding conductor 200.

[0040] In this embodiment, an optical fiber sensor 102 is installed in the mounting cavity 106 between two adjacent sets of conductors 200 and the protective layer 100, and is connected to the conductors 200 in contact. Utilizing the high sensitivity of the optical fiber sensor 102, the deformation state and stress distribution of the conductors 200 under torsion, tension, and other conditions can be sensed in real time, providing data support for monitoring the cable's operational status. This design allows the sensor to directly acquire signals of changes in the mechanical properties of the conductors 200, promptly detecting potential problems such as broken wires and poor contact, achieving dynamic monitoring of the cable's health status. This is particularly suitable for harsh scenarios such as offshore wind power where maintenance is difficult. Without affecting the cable's original torsion resistance structure, intelligent monitoring improves the reliability and safety of the system, ensuring the long-term stable operation of the cable.

[0041] It should be noted that the mounting cavity 106 is filled with a filler to ensure the stability of the fiber optic sensor 102 within the mounting cavity 106.

[0042] In the aforementioned torsion-resistant cable, the protective layer 100 includes an insulating sleeve 103 and a protective sleeve 104, with the insulating sleeve 103 located inside the protective sleeve 104.

[0043] In this embodiment, the protective layer 100 adopts a double-layer structure design of insulating sleeve 103 and protective sleeve 104, achieving dual protection through functional partitioning. The inner insulating sleeve 103 tightly wraps the conductor 200, providing reliable electrical insulation performance, preventing leakage or short circuit between conductors 200, and ensuring power transmission safety. The outer protective sleeve 104, with its strong mechanical strength and environmental resistance, resists external wear, impact, corrosion (such as salt spray and oil), and extreme temperature effects, creating a stable operating environment for the internal structure. The synergistic effect of the two layers enables the cable to meet electrical insulation requirements while withstanding physical stress and environmental erosion under complex working conditions, significantly improving overall service life and the breadth of applicable scenarios while ensuring conductivity reliability.

[0044] In the aforementioned torsion-resistant cable, the insulating sleeve 103 is made of ethylene propylene rubber insulation, and the protective sleeve 104 is made of chlorinated polyethylene.

[0045] In this embodiment, the insulating sleeve 103 is made of ethylene propylene rubber insulation, and the protective sleeve 104 is made of chlorinated polyethylene, forming a complementary double-layer protection system. Ethylene propylene rubber insulation, with its excellent electrical insulation and weather resistance, effectively isolates electrical conduction between conductors 200 and resists the effects of ultraviolet radiation, ozone, and extreme temperatures on insulation performance, ensuring long-term stable power transmission safety. The chlorinated polyethylene protective sleeve 104, with its good mechanical strength, chemical corrosion resistance, and aging resistance, withstands external friction, impact, and corrosion from salt spray, oil, etc., providing durable physical protection and an environmental barrier for the internal structure. The combination of these two materials enables the cable to maintain insulation stability during high-frequency torsion and withstand the long-term testing of harsh environments such as offshore wind power, achieving synergistic optimization of electrical performance and mechanical protection.

[0046] In the aforementioned type of torsion-resistant cable, a non-woven fabric layer 105 is also provided inside the insulating sleeve 103.

[0047] In this embodiment, a non-woven fabric layer 105 is provided inside the insulating sleeve 103. Utilizing the soft and porous properties of the non-woven fabric, it effectively fills the gap between the conductor 200 and the insulating sleeve 103, providing uniform buffer protection for the conductor 200 and reducing direct frictional loss between the conductor 200 and the insulation layer during torsion. Simultaneously, the non-woven fabric layer 105 helps disperse local stress, enhances the tightness of the insulating sleeve 103's wrapping around the conductor 200, and improves the stability of the insulation structure. Its fibrous structure can also absorb small amounts of moisture or oil, reducing the impact of external corrosive media on the conductor 200. Without increasing the overall stiffness of the cable, through flexible support and environmental isolation, it further optimizes the electrical insulation performance and mechanical protection effect of the insulating sleeve 103, ensuring long-term reliable operation of the cable under complex working conditions. It should be noted that in this utility model, descriptions involving "first," "second," or "a" are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. In the description of this utility model, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal connection of two components or the interaction between two components, unless otherwise explicitly specified. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0048] Furthermore, the technical solutions of the various embodiments of this utility model can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0049] The specific embodiments described herein are merely illustrative examples illustrating the spirit of this utility model. Those skilled in the art to which this utility model pertains may make various modifications or additions to the described specific embodiments or use similar methods to replace them, without departing from the spirit of this utility model or exceeding the scope defined by the appended claims.

Claims

1. A kink-resistant cable, characterized by The utility model relates to a kind of optical fiber sensor, including: Protective layer, the protective layer is internally hollow structure; Conductor is arranged in the protective layer, the quantity of the conductor is multiple groups, multiple groups of the conductor is annular distribution, each group of the conductor includes the wrapping tape of internally hollow structure, at least one ring of the wrapping tape is arranged in multiple strands of annular distribution, when the number of turns of the strand is multiple turns, the circle center of multiple turns of the strand is located at the same point, and the cavity is left in the strand of innermost circle;Each circle of the strand is that two adjacent strands are connected;The strand is made of flexible material.

2. A kink resistant cable according to claim 1, wherein, The conductor is formed by multiple strands of wire being twisted in the same direction.

3. A kink resistant cable according to claim 2, wherein, The strand is formed by multiple guide wires being twisted in the same direction, and the twisting direction of the strand is the same as the twisting direction of the conductor.

4. A kink resistant cable according to claim 3, wherein, The material of the guide wire is aluminum.

5. A kink resistant cable according to claim 1, wherein, The center position of the protective layer is provided with a tensile element, and the conductor is distributed around the tensile element and connected with the tensile element.

6. A kink resistant cable according to claim 1, wherein, The conductor is provided with rubber-coated cotton cloth outside to form a wrapping tape.

7. A kink resistant cable according to claim 1, wherein, The installation cavity is formed between the adjacent two groups of conductors and the protective layer, and the optical fiber sensor is arranged in the installation cavity and connected with the corresponding conductor.

8. A kink resistant cable according to claim 1, wherein, The protective layer includes an insulating sleeve and a protective sleeve, and the insulating sleeve is located in the protective sleeve.

9. A kink resistant cable according to claim 8, wherein, The material of the insulating sleeve is ethylene-propylene rubber insulation, and the material of the protective sleeve is chlorinated polyethylene.

10. A kink resistant cable according to claim 8, wherein, The insulating sleeve is further provided with a non-woven fabric layer.

Images